Mail Assembly for Flats Transportation

ABSTRACT

A mail assembly and a method of packing an envelope with the mail assembly. The mail assembly having a mail tray that is sized and shaped to be inserted into a flat envelope and a plurality of protrusions extending distally out of the mail tray and forming at least one holding area on the mail tray for retaining at least one item, wherein each of the plurality protrusions is disconnected from the other protrusions.

BACKGROUND INFORMATION

The United States Postal Service (USPS), United Parcel Service (UPS), and Federal Express (FedEx), among other package delivery companies use the term “flats” to describe envelopes that can be used to transport a variety of items (e.g., advertising items, promotional items, product samples). The cost of mailing or shipping packages can be high, which is why numerous businesses have turned to flats for mailing materials. Flats are a cheaper alternative to mailing packages. Flats are less expensive to mail than non-flat materials (NFMs) because automated mailing procedures may be used with flats. Automated mailing procedures may include rollers, nips, sorting machines, conveyors, robotics, marking machines, channeling systems, and S-shaped pathways requiring significant deflection of envelopes and packages.

SUMMARY

Exemplary embodiments include a mail assembly. The mail assembly includes a mail tray that is sized and shaped to be inserted into a flat envelope and a plurality of protrusions extending distally out of the mail tray and forming at least one holding area on the mail tray for retaining at least one item, wherein each of the plurality protrusions is disconnected from the other protrusions. In some exemplary embodiments, the mail assembly is constructed from a fiber based material, a petroleum based plastic material, or a plant based plastic material.

The plurality of protrusions may be arranged in a predetermined pattern to form the at least one holding area. The predetermined pattern may be configured to form the at least one holding area to retain a single item or to retain multiple items. In other exemplary embodiments, the at least one holding area is formed in an interior of one of the protrusions.

In exemplary embodiments, each of the protrusions may extend an equal distance from the mail tray. In other exemplary embodiments, the mail assembly has a first set of protrusions extending a first distance from the mail tray and a second set of protrusions extending a second distance from the mail tray. In some exemplary embodiments, the first set of protrusions are arranged around a perimeter of the mail tray.

In exemplary embodiments, each of the protrusions may have the same shape. In other exemplary embodiments, the mail assembly has a first set of protrusions having a first shape and at least one second protrusion having a second shape, wherein the first shape is different from the second shape. In some exemplary embodiments, the protrusions have a conical frustum shape. In some exemplary embodiments, the protrusions taper from a proximal end on a top surface of the mail tray to a distal end. In some exemplary embodiments, the protrusions have a distal end that is flat. In some exemplary embodiments, the mail tray includes at least one hole that penetrates through the mail tray.

In some exemplary embodiments, the mail tray has a rectangular shape. In some exemplary embodiments, the mail tray has a shape that is designed to be inserted into a flat envelope such that the flat envelope has a substantially uniform thickness.

In still other exemplary embodiments, a method of packing an envelope with an item to be mailed is described. The method includes selecting a mail assembly comprising a mail tray and a plurality of protrusions extending distally out of the mail tray to forming at least one holding area on the mail tray, wherein the mail assembly is sized and shaped to correspond to the envelope, inserting the item into the holding area on the mail tray and inserting the mail assembly including the item into the envelope.

BRIEF DESCRIPTIONS OF DRAWINGS

FIG. 1 shows a perspective view of a mail assembly according to various exemplary embodiments.

FIG. 2 shows a side view of the mail assembly of FIG. 1 according to various exemplary embodiments.

FIGS. 3A-D show various side views of a protrusion of the mail assembly of FIG. 1 according to various exemplary embodiments.

FIG. 4 shows a perspective view of a second mail assembly according to various exemplary embodiments.

FIGS. 5A-B show a side views of protrusions of the mail assembly of FIG. 4 according to various exemplary embodiments.

FIG. 6 shows a perspective view of a third mail assembly according to various exemplary embodiments.

FIG. 7 shows the mail assembly of FIG. 4 inserted into a flat envelope according to various exemplary embodiments.

FIG. 8 shows a perspective view of a third mail assembly according to various exemplary embodiments.

DETAILED DESCRIPTION

The exemplary embodiments may be further understood with reference to the following description and the related appended drawings, wherein like elements are provided with the same reference numerals. The exemplary embodiments are related to a mail assembly including a mail tray and protrusions. The protrusions extend from the tray without having a connecting geometry.

As described above, mailing or shipping entities use automated mailing procedures for flats. In order to pass through the machines associated with automated mailing procedures, flats are typically required to be rectangular, flexible and of uniform thickness. There may also be additional requirements that are determined by each individual delivery company. However, an issue arises for shippers because many materials and/or products that the shipper wants to send using the less expensive flats mailing do not conform to the flats requirements. Thus, the exemplary embodiments provide a mail assembly that conforms to the flats requirements and may be used to ship multiple different types of materials and/or products.

FIG. 1 shows a perspective view of a mail assembly 100 according to various exemplary embodiments. The mail assembly 100 includes a mail tray 102 and multiple protrusions 120, extending distally out of the mail tray 102. In this example, the mail tray 102 is rectangular in shape, including a first side 104, a second side 106, a third side 108 and a fourth side 110, forming a perimeter. The first side 104 and second side 106 are parallel to each other and shorter than the third side 108 and the fourth side 110, which are parallel to one another. The dimensions of the mail tray 102 may be determined by dimensions of a flat into which the mail tray 102 is to be inserted. For example, in one exemplary embodiment, the mail tray 102 will be 12½″ by 9½″ to comply with equal measurements of a FedEx flat envelope. Those of skill in the art will understand that the dimensions of the mail tray 102 may be slightly smaller than the envelope itself, e.g., by ⅛ to ¼ inches, so that the mail tray 102 will fit into the flat envelope and allow the flat envelope to be sealed. In addition, it should be understood that the above dimensions are only exemplary and that the mail tray 102 may have any dimensions that correspond to a flat envelope size that is offered by a delivery company.

The protrusions 120 extend from the mail tray 102 without having any connecting geometry, meaning that each protrusion 120 is independent from any other protrusion 120, e.g., a protrusion 120 is not connected to any other protrusion 120. As will be explained in greater detail below, this lack of connecting geometry allows the mail assembly 100 to remain flexible when inserted into a flat envelope. The protrusions 120 may have a height (e.g., extend distally from the mail tray 102) consistent with the allowed thickness of the flat envelope. In one exemplary embodiment, a flat envelope has a thickness requirement of ¾″. Thus, in one example, the protrusions 120 may be ¾″. Those of skill in the art will understand that the height of the protrusions 120 may be slightly less than the flat envelope requirement to account for the thickness of the mail tray 102 and the thickness of the flat envelope itself. In addition, it should be understood that the above height is only exemplary and that the protrusions 120 may have any height that correspond to a flat envelope thickness requirement.

In the example of FIG. 1, the protrusions 120 are arranged in a pattern to form various holding areas for the items to be shipped, e.g., holding areas 130, 132 and 134. These holding areas 130, 132 and 134 may each hold one or more items, or a single item may occupy one or more holding areas 130, 132 and 134. It should be understood that when an item is placed on the mail tray 102 in one or more of the holding areas 130, 132 and 134, the item should not extend beyond the distal end 124 of the protrusions 120, e.g., the mail assembly 100 holding shipment items will have a generally uniform maximum thickness that comprises the thickness of the mail tray 102 plus the height of the protrusions 120. As will be described in greater detail below, in some exemplary embodiments, one or more of the protrusions 120 may have varying heights. However, this will not change the maximum thickness of the mail assembly 100 because multiple protrusions 120 will have a same maximum height such that when the mail assembly 100 is placed into a flat envelope, the flat envelope will have a generally uniform thickness.

As described above, FIG. 1 shows one exemplary pattern for arranging the protrusions 120. However, it should be understood that the protrusions 120 may be organized into a variety of predetermined patterns, depending on the item being shipped. The predetermined pattern may allow the items to be oriented in specific direction so that they may be mailed using a flat envelope. For example, the protrusions 120 may be aligned in parallel rows creating parallel holding areas for mailing of pens. In another example, the protrusions 120 may be arranged such that a square or rectangular holding area is created in a middle of the mail tray 102 for mailing square or rectangular shaped items. Those skilled in the art will understand that predetermined patterns of protrusions 120 may be developed based on the items that are to be shipped and these patterns may create holding areas having regular shapes, irregular shapes, symmetrical shapes, asymmetrical shapes, etc.

The mail assembly 100 may be constructed from any material that allows the mail assembly to flex or bend as the mail assembly 100 (when in a flat envelope) moves through the automated machinery of the delivery company. Examples of materials may include fiber based materials, petroleum based plastic materials (e.g., polyethylene, polypropylene, polystyrene, polyester, nylon, acrylic, etc.), and plant based plastic materials (e.g., polylactic acid, cellulose acetate, etc.).

FIG. 2 shows a side view of the mail assembly 100 of FIG. 1 according to various exemplary embodiments. It may be considered that FIG. 2 shows a view of the first side 104 of the mail tray 102. In this example, the protrusions 120 are of a uniform height and that height (including the thickness of the mail tray 102) complies with the requirements of the flat envelope into which the mail assembly 100 is to be inserted. The protrusions 120 may be formed into any three-dimensional shape (e.g., a cylinder, a cone, a prism, a frustum, etc.). In this exemplary embodiment, the protrusions 120 are shaped as conical frustums, wherein each protrusion 120 extends from a proximal end 122, on a top surface of the tray 102, to a distal end 124, with a lateral side 126 therebetween. Thus, when the mail assembly 100 is inserted into a flat envelope, a bottom surface of the mail tray 102 may contact a first inside surface of the flat envelope and the distal ends 124 of the protrusions may contact a second inside surface of the flat envelope. In this arrangement, the conical frustum shape that has a flat distal end 124 (or any shape having a flat distal end) may have an advantage over protrusion 120 shapes that do not have a flat distal end 124 because the non-flat distal ends will have more pressure at a point where the shape contacts the flat envelope as opposed to the flat distal end 124 that will more evenly distribute the pressure on the flat envelope.

In the example of FIG. 2, each protrusion 120 tapers from the proximal end 122 to the distal end 124 (e.g., a diameter of the protrusion 120 at the proximal end 122 will be greater than a diameter of the protrusion 120 at the distal end 124). However, even though the exemplary embodiments are described as having conical frustum shaped protrusions 120, this is not a requirement of the mail assembly 100. Other shapes may also be used for the protrusions and satisfy the flexibility parameters for use in a flat envelope, including irregular shapes. Some examples of different shaped and/or sized protrusions will be provided below.

FIG. 3A shows a side view of the protrusion 120 in a conical frustum shape. The protrusion 120 may cover varying amounts of area of the mail tray 102 (e.g., the diameter of the protrusion 120 at the proximal end 122 may be varied) either on the same mail tray 102 or between different types of mail trays 102. These different sizes of protrusions 120 may be used to form particular shapes for holding areas (e.g., holding areas 130, 132, 134) or to result in a different level of flexibility for the mail assembly 100. Similarly, the protrusions 120 may have varying amounts of taper between protrusions 120 on the same mail assembly 120 or between different types of mail assemblies 100. Again, these variances may be made based on the type of item to be held by the mail assembly 100 or based on the flexibility characteristics of the mail assembly 100. The protrusions 120 may be hollow, solid, or filled to any amount therebetween. Typically, hollow would be preferred because it will result in less material being used. However, there may be circumstances where partially completely filled protrusions 120 may be appropriate. FIGS. 3B-3D show transparent side views of the protrusion 120 according to different exemplary embodiments. FIG. 3B shows a protrusion 120 that is generally hollow, wherein a majority of the interior volume of the protrusion is empty space (e.g., 90% of the interior volume is empty). FIG. 3C shows a protrusion 120 that may be solid. FIG. 3D shows a protrusion 120 that is partially filled (e.g., approximately 50% of the volume is empty space).

FIG. 4 shows a perspective view of a second mail assembly 200 according to various exemplary embodiments. The mail assembly 200 is substantially similar to the mail assembly 100 and comprises a mail tray 202 capable of retaining a variety of items. However, in this exemplary embodiment, there are first protrusions 220 and second protrusions 230 that extend distally out of the mail tray 202. The first protrusions 220 and second protrusions 230 are substantially similar to the protrusions 120 in terms of shape. However, in this example the height of the first protrusions 220 is less than the height of the second protrusions 230. In FIG. 4, the height difference is exaggerated to illustrate that there is a difference in height. In an actual embodiment, the height difference will be slight, e.g., ⅛ to ¼ inches. As shown in FIG. 4, the first protrusions 220 (that extend less than the second protrusions 230) line a perimeter of the mail tray 202. The reason for this slight lessening of the height of the perimeter protrusions 220 is that this may allow the mail assembly 200 to be placed into a flat envelope more easily. For example, as described above, the flat envelope may have a maximum thickness and the thickness of the combined mail tray 202 and the second protrusions 230 may correspond to this maximum thickness. However, because the thickness of the combined mail tray 202 and the first protrusions 230 is slightly less and because this is on the perimeter of the mail assembly 200 that will be inserted first into the flat envelope, this may be inserted more easily into the opened flat envelope and then be used to guide the slightly thicker portion of the mail assembly 200 including the second protrusions 230 into the flat envelope. As described above, while the thickness of the loaded flat envelope is supposed to be uniform, a minor variance between the perimeter and the center should not be enough to disqualify the mail assembly 200 from meeting the flat requirements of most delivery services and will aid the shipper in packaging the products within the flat envelope.

FIGS. 5A-B show a side views of protrusions 220 and 230 of the mail assembly 200 of FIG. 4, respectively, according to various exemplary embodiments. FIG. 5A shows the first protrusion 220 extending from a proximal end 222, on a top surface of the tray 202, to a distal end 224, which may contact an inside surface of the flat, with a lateral side 226 therebetween. FIG. 5B shows the second protrusion 230 extending from a proximal end 232, on a top surface of the tray 202, to a distal end 234, which may contact an inside surface of the flat, with a lateral side 236 therebetween. In this example, the height of the protrusion 220 is less than a height of the second protrusion 230. Also, in this example, a tapering angle of the first protrusion 220 is greater than a tapering angle of the second protrusion 230. However, this differing tapering angle is only exemplary, and the same tapering angle may be used. Additionally, although in this exemplary embodiment the first protrusion 220 and the second protrusion 230 are conical frustums, the first protrusions 220 may have a different shape when compared to a shape of the second protrusions 230.

FIG. 6 shows a perspective view of a third mail assembly 300 according to various exemplary embodiments. The third mail assembly 300 of FIG. 6 is substantially similar to the second mail assembly 200 of FIG. 4 in that it includes a mail tray 302, first protrusions 320 of a first height and second protrusions 330 of a second height. The tray 302 further comprises holes 340. The holes 340 may include additional advantages for the mail assembly 300. For example, by including the holes 340, less material may be used to manufacture the mail assembly 300. The holes 340 may also be used to more easily handle the mail assembly 300. In addition, the holes 340 may provide more clearance for the items to be retained in the mail tray 302, e.g., the items to be retained in the mail tray 302 may have a portion that extends into one or more of the holes 340 such that the item will not extend beyond the distal end of the protrusions 320 or 330. Although the exemplary embodiment shows two holes 340, any number of holes 340 may be used and may be placed in various locations within the perimeter of the mail tray 302 to accommodate the particular items being shipped. Additionally, although the holes 340 in the exemplary embodiment are circular, the holes 340 may be of a different shape.

FIG. 7 shows the mail assembly 200 of FIG. 4 inserted into a flat envelope 10 according to various exemplary embodiments. Although any of the previously described mail assemblies (100, 200 and 300) may be inserted into the flat envelope 10, FIG. 7 shows a perspective view of the example mail assembly 200 being inserted into the envelope 10. The envelope 10 includes a perimeter 12, a top portion 14, a bottom portion 16 and an opening 18. The perimeter 12 includes a first longitudinal edge 22, a second longitudinal edge 24 and a lateral edge 26. The lateral edge 26 is parallel to the opening 18 and opposite of the opening 18. The first longitudinal edge 22 and second longitudinal edge 24 connect the lateral side 26 to the opening 18. The top portion 14 and bottom portion 16 are connected to one another such that a minimum thickness occurs along the perimeter 12. According to the USPS, the envelope 10 must have at least one dimension that is greater than eleven and a half inches in length, six and one eighth inches in height, or one-quarter of an inch in thickness. Maximum dimensions of the envelope 10 are fifteen inches in length, twelve inches in height, and three-quarters of an inch in thickness, wherein the length is the dimension parallel to the address as read, and the height is the dimension perpendicular to the length. These dimensions are only provided to provide context for the mail assembly 200 and different delivery companies may have different requirements for their flat envelopes. The mail assembly 200 may be sized and shaped to conform to a variety of the dimensions of the envelope 10.

The mail assembly 200 may have a predetermined pattern of the second protrusions 230 for mailing items that must be held in specific orientations to be mailed in the envelope 10. The mail assembly 200, along with the items (not shown) on the tray 202, may be inserted through the opening 18 until the mail assembly 200 abuts the lateral edge 26. As one of ordinary skill in the art will understand, the first height of the first protrusions 220 is less than the second height of the second protrusions 230 to better enable the mail assembly 200 insertion into the envelope 10. The first height conforms to a lower thickness of the envelope 10 along the perimeter 12. The second height conforms to a maximum thickness of the envelope 10, giving a greater clearance for the items on the tray 202. Once the mail assembly 200 is completely inserted into the envelope 10, the opening 18 may be sealed to be ready for pickup by the delivery company.

As described above, the mail assembly 200 (and the mail assemblies 100 and 300) not only conform to the size requirements of the flat envelope 10, but also conform to the flexibility requirements for using automated machinery to sort and otherwise process the loaded flat envelope 10. For example, after the delivery company picks up the loaded flat envelope 10, the delivery company may place the loaded flat envelope 10 into an automated system for sorting and processing (e.g., weighing, placing in trays, applying barcodes, etc.). This automated system may have various machines and conveyors through which the loaded flat envelope 10 travels. These machines and conveyors may bend, twist, and flex the loaded flat envelope 10 as it traverses the automated system. Since the mail assembly 200 does not have connecting geometry between the different protrusions 220 and/or 230, the mail assembly 200 within the loaded flat envelope 10 may also be bent, twisted, and flexed without causing the mail assembly 200 to break, crack or otherwise damage the flat envelope 10. Thus, the mail assemblies according to the exemplary embodiments, allow for the flats requirements of delivery companies to be satisfied, allowing a shipper to use the lower cost flats delivery.

FIG. 8 shows a perspective view of a third mail assembly 800 according to various exemplary embodiments. The mail assembly 800 is substantially similar to the mail assemblies 100 and 400 and comprises a mail tray 802 capable of retaining a variety of items. However, in this exemplary embodiment, there are first protrusions 820 and a second protrusion 830 that extend distally out of the mail tray 802. The first protrusions 820 are substantially similar to the protrusions 120 in terms of shape. The second protrusion 830 is a different shape. Specifically, the protrusion 830 has a rectangular shape, e.g., the 4 walls of the rectangle are a single protrusion. However, like the other protrusions described herein, the protrusion 830 is also disconnected from any other protrusion.

In this example, an interior of the rectangular protrusion 830 may be considered a holding area 835 that is configured to hold the product(s) for mailing. Thus, in this example, multiple protrusions do not form a holding area as in the example of FIG. 1, but rather a single protrusion may form a holding area. In another example, a single mail assembly may comprise holding areas that are formed from a single protrusion and other holding areas that may be formed from multiple protrusions depending on the product or products that are being mailed.

This example also shows that the protrusions may take the form of any shape. For example, the rectangular protrusion 830 with the rectangular holding area 835 may be used for products that have a rectangular shape, e.g., a SIM card for a mobile device. In another example, the product that is being shipped may be a set of adhesive glow-in-the-dark plastic stars that are designed to attach to the ceiling of a child's room. In this type of example, the protrusions may take the form of a star-shape where the interior holding area is star-shaped and one or more plastic stars may be placed in the star-shaped protrusions for mailing. From these examples, it will be clear to those skilled in the art that the protrusions may be any shape.

Although this application described various embodiments each having different features in various combinations, those skilled in the art will understand that any of the features of one embodiment may be combined with the features of the other embodiments in any manner not specifically disclaimed or which is not functionally or logically inconsistent with the operation of the device or the stated functions of the disclosed embodiments.

It will be apparent to those skilled in the art that various modifications may be made in the present disclosure, without departing from the spirit or the scope of the disclosure. Thus, it is intended that the present disclosure cover modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalent. 

1. A mail assembly, comprising: a mail tray that is sized and shaped to be inserted into a flat envelope; and a plurality of protrusions extending distally out of the mail tray and forming at least one holding area on the mail tray for retaining at least one item, wherein each of the plurality protrusions is disconnected from the other protrusions.
 2. The mail assembly of claim 1, wherein the plurality of protrusions are arranged in a predetermined pattern to form the at least one holding area.
 3. The mail assembly of claim 2, wherein the predetermined pattern is configured to form the at least one holding area to retain a single item.
 4. The mail assembly of claim 2, wherein the predetermined pattern is configured to form the at least one holding area to retain multiple items.
 5. The mail assembly of claim 1, wherein each of the protrusions extends an equal distance from the mail tray.
 6. The mail assembly of claim 1, wherein the plurality of protrusions comprises: a first set of protrusions having a first shape; and at least one second protrusion having a second shape, wherein the first shape is different from the second shape.
 7. The mail assembly of claim 1, wherein the at least one holding area comprises an interior of one of the protrusions.
 8. The mail assembly of claim 1, wherein the plurality of protrusions comprises: a first set of protrusions extending a first distance from the mail tray; and a second set of protrusions extending a second distance from the mail tray, wherein the first distance is less than the second distance.
 9. The mail assembly of claim 8, wherein the first set of protrusions are arranged around a perimeter of the mail tray.
 10. The mail assembly of claim 1, wherein the tray comprises a rectangular shape.
 11. The mail assembly of claim 1, wherein, when the mail assembly is inserted into the flat envelope, the flat envelope has a substantially uniform thickness.
 12. The mail assembly of claim 1, wherein the protrusions comprise a conical frustum shape.
 13. The mail assembly of claim 1, wherein the protrusions taper from a proximal end on a top surface of the mail tray to a distal end.
 14. The mail assembly of claim 1, wherein the protrusions comprise a distal end that is flat.
 15. The mail assembly of claim 1, wherein the mail tray includes at least one hole that penetrates through the mail tray.
 16. The mail assembly of claim 1, wherein the mail assembly comprises one of a fiber based material, a petroleum based plastic material, or a plant based plastic material.
 17. A method of packing an envelope with an item to be mailed, comprising: selecting a mail assembly comprising a mail tray and a plurality of protrusions extending distally out of the mail tray to forming at least one holding area on the mail tray, wherein the mail assembly is sized and shaped to correspond to the envelope; inserting the item into the holding area on the mail tray; and inserting the mail assembly including the item into the envelope. 